Empowering intelligence, ensuring chemical safety: Zhongyun Technology's predictive maintenance solution strengthens the safety barrier in chemical production.

Recently, the National Emergency Management Department released its interpretation of the "Construction Requirements for Digital and Intelligent Applications in Safety Risk Control of Hazardous Chemicals by 2025," clearly identifying real-time monitoring of critical pumps and motors as a mandatory application scenario. Specifically, for high-temperature pumps handling media with temperatures ≥260°C, as well as liquid hydrocarbon transfer pumps, real-time monitoring of parameters such as vibration and temperature, coupled with anomaly alerts, is required. This move pushes the intelligent safety management of the hazardous chemicals industry to a pivotal milestone.

Wuhan Zhongyun Kangchong Technology Co., Ltd. (hereinafter referred to as "Zhongyun Technology") is deeply engaged in the field of predictive maintenance for industrial equipment. Leveraging a mature operations and maintenance technology system, the company customizes intelligent monitoring solutions tailored specifically for hazardous chemical enterprises, addressing the challenges of traditional O&M practices and helping these companies effectively meet regulatory requirements.

Traditional IT Operations Pain Points: The "Safety Weakness" in Hazardous Chemical Production

In hazardous chemical production, the stable operation of critical equipment such as reaction vessels, transfer pumps, and compressors directly determines production safety—but traditional operation and maintenance models have obvious limitations.

• Manual inspections pose significant risks: Hazardous chemical facilities feature complex environments with numerous areas of high temperature and high pressure, making it difficult for human inspectors to achieve full coverage. This often leads to missed detections and inaccurate assessments, while also exposing personnel to highly dangerous conditions, thereby increasing safety risks.
• Fault warning is delayed: Relying on a passive "post-failure maintenance" approach prevents early detection of potential equipment risks, making minor faults prone to escalating into production disruptions or safety incidents. For instance, if aging pump seal components go unnoticed, it could lead to medium leakage.
• Data management is fragmented: Operational data from different devices are scattered across independent systems, making it impossible to perform unified analysis or identify correlations. As a result, it’s challenging to create comprehensive equipment health profiles, which ultimately impacts the accuracy of operations and maintenance decision-making.

Zhongyun Technology Solution: The "Smart Protection Network" for Hazardous Chemical Equipment

Addressing industry pain points, Zhongyun Technology has integrated end-to-end technologies spanning "sensing, transmission, analysis, and early warning," launching a predictive maintenance solution for hazardous chemical equipment, in order to The Three Core Elements Capability ensures safety.

1. Full-Scenario Adaptation: Precisely Collecting Key Data

The solution is equipped with multiple high-precision sensors tailored to the needs of hazardous chemical scenarios:

• High-Temperature Vibration and Temperature Sensor: Withstands up to 260°C, accurately capturing the vibration frequency and temperature of high-temperature pumps and reaction vessels—perfectly aligning with the critical equipment monitoring standards outlined in the "Construction Requirements."
• Explosion-proof multi-parameter sensor: Complies with Ex d IIB T4 Ga explosion-proof rating, capable of monitoring pipeline pressure and medium flow rate to prevent leaks caused by pressure abnormalities.
• Flexible expansion interface: Supports the integration of parameters such as rotational speed and humidity, enabling the construction of a comprehensive device operation database that provides complete data support for diagnostics.

II. Stable Transmission: Ensuring Uninterrupted Data

Given the complex network characteristics of hazardous chemical plant areas, multi-mode wireless transmission technology is employed:

• 5G+LoRaWAN Dual-Mode Communication: 5G enables high-speed data uploads, while LoRaWAN caters to long-distance and low-power requirements—eliminating the need for complex wiring and reducing both construction costs and safety risks.
• Local + Cloud Dual Backup: Data is synchronized to both the local edge gateway and the cloud server, preventing data loss caused by network interruptions and ensuring 24/7 continuous monitoring.

III. AI Intelligence: Proactive Risk Alerts

Leveraging the company's independently developed equipment health management platform to achieve deep data application:

• Real-time visualization: The PC and mobile app intuitively display metrics such as vibration velocity values and bearing health index (HI), enabling operations and maintenance personnel to monitor equipment status without needing to be on-site.
• Predictive diagnostics: Built-in failure models for hazardous chemical equipment compare historical and real-time data to provide early warnings—7 to 14 days in advance—of issues such as bearing wear and abnormal motor noises, with an accuracy rate exceeding 92%.
• Coordinated Alerting: When data anomalies occur, immediately send alerts via SMS and app push notifications, while simultaneously activating the factory’s audio-visual alarms to enable a rapid response and prevent the issue from escalating.

Application Case: Safety Upgrade at a Petrochemical Enterprise

A large petrochemical enterprise in Wuhan, primarily engaged in the production of liquid hydrocarbons and aromatics, relies on 20 critical liquid hydrocarbon transfer pumps as its core equipment. Previously, due to a lack of effective monitoring, abnormal pump vibrations led to media leaks, forcing a three-day production halt and resulting in substantial losses. However, after adopting the Zhongyun Technology solution in 2024, the company has successfully achieved an upgrade in operations and maintenance:

• Rapid Deployment: Utilizing a magnetic quick-mount system, sensor installation on 20 pump units was completed within 2 days—without requiring any production downtime.
• Data Integration: Integrate pump operation data into the enterprise MES system to enable collaborative analysis of "equipment status and production progress."
• Precise Early Warning: Setting vibration ≥4.5mm/s and temperature ≥120℃ as thresholds, we successfully issued 3 early warnings of bearing wear and 2 alerts for seal leakage within 6 months, enabling timely replacement of components to prevent failures.
• Significant achievements: The frequency of manual inspections has dropped from three times a week to once a month, reducing operational and maintenance costs by 40%, and successfully passing the 2024 special safety inspection for hazardous chemicals.

With the intelligent upgrade of hazardous chemical safety supervision, Zhongyun Technology will continue to optimize its solutions, covering scenarios such as chemical parks and storage tank areas, and provide end-to-end "design-deployment-operation & maintenance" services. We look forward to collaborating with more hazardous chemical enterprises to drive the industry’s transformation from "reactive maintenance" to "proactive prevention," ultimately building a safe and efficient production environment. For detailed information about our solutions, please visit the company website to explore customized services.